Air intake flow device and system

ABSTRACT

An intake flow device and system is disclosed. The flow device may be cylindrically shaped and flexible. An intake conduit may be fitted around the flow device, such that the intake conduit may retain a large diameter for increased air flow, rather than necking down. The flow device may incorporate compression ribs around its outer circumference for positively mating with the air intake conduit. The flow device may also include graduated portions and be configured to direct air to an air metering device. Guide vanes may also be provided within the flow device to control and direct air to the air metering device.

FIELD OF THE INVENTION

The present invention is generally related to air intake flow devicesand systems, and more particularly to devices and systems for adaptinglarge-diameter air intake conduits and flow components to vehicles. Inone embodiment, a collar may be configured to mate a large-diameter airintake conduit to a smaller-diameter turbocharger intake. In anotherembodiment, a collar may be configured to direct air flowing through alarge-diameter conduit to an air metering device for accuratemeasurement.

BACKGROUND ART

Relatively large internal diameter air intake kits are frequently usedto increase the performance of existing internal combustions engines,such as those used in modern vehicles. The intake kits may haverelatively larger internal diameters than original equipmentmanufacturer intakes to increase the volume of air delivered to theengine and to reduce pressure losses from the air filter to the engine'sair intake or turbocharger inlet. While such air intakes may initiallyhave intake conduits with larger internal diameters than correspondingoriginal equipment manufacturer parts, they frequently taper down tomate with the engine's intake, such as a turbocharger, which may have anintake flange with a relatively smaller external diameter. For example,a turbocharger may have an air intake flange with an external diameterof approximately 2.875 inches. If the intake conduit has an initialinternal diameter of 3.875 inches, such as where it mates to an airfilter, that internal diameter will frequently reduce down toapproximately 2.875″ to mate with the intake flange of the turbocharger.When the diameter is shrunk from one end of the conduit to the next, airflow may be reduced, there may be undesirable steps in the conduit,and/or there may be flow inhibiting shapes present in the conduit. Thismay cause undesirable interruptions to the flow of intake air,undesirable pressure differentials, and may detrimentally impactperformance. Further, it may be economically desirable for an air intakemanufacturer to produce air intakes generally having a fixedconfiguration. Accordingly, the internal diameter of the portion of theair intake conduit that mates to a turbocharger of a particular vehiclemay be too large for another vehicle. Further, when a manufacturerchanges the intake flange dimensions of, for example, a turbocharger, anew intake conduit may need to be made to accept the newly-sized intakeflange. It may therefore be prohibitively expensive for an air intakeconduit manufacturer to constantly be retooling its products for onlyslightly different applications. Additionally, a coupler may need to beused to bridge the intake flange of the turbocharger with the intakeconduit. The coupler may incorporate ridges therein which may furtherimpede and/or disturb air flow. In addition, the coupler may need to becoupled on one side to the air intake conduit, and on the other side tothe intake flange-necessitating two clamps to secure the air intake tothe turbocharger. What is needed is an intake flow device configured toefficiently transfer air from an air intake conduit to an intake flange.

While relatively larger internal diameters of aftermarket intake kitsmay increase the volume of air delivered to the engine, such air intakesmay detrimentally impact the metering of air, upstream of theturbocharger, or otherwise. In particular, by increasing the internaldiameter of air intake conduits, the velocity of the air travelingthrough an air metering device, such as a mass air flow sensor, maydecrease or change character and cause the air metering device toincorrectly report the volume, mass, or speed of the air flowing throughthe larger-diameter conduit. This problem may manifest if the originalair metering device, designed to measure air flowing through a smallerdiameter air intake conduit, is used in connection with an aftermarketair intake conduit. Such misreporting can cause the engine to runpoorly, and even cause damage to the engine, such as in the case of alean condition. What is needed is an intake flow device configured tocondition air flow to an air metering device in the case of at leastlarger-diameter intake conduits.

SUMMARY

Non-exclusive, non-limiting embodiments of the invention illustratedherein provide an intake flow device in the form of a collar having aninner surface with a first diameter, outer surface with a seconddiameter, and a graduated side surface for directing air flow. The flowdevice may be configured to fit onto a turbocharger's compressor intakeflange or onto the intake flange of a normally-aspirated engine. Thecollar may be formed from a rubber-like material such as polyurethane,silicone, or other suitable materials designed to comply with, andeffectively seal the engine's intake tract in the proximity of theintake opening, such as the turbocharger's compressor intake.

In application, the flexible collar may be placed over the intake flangeof, for example, a turbocharger's compressor. The fit may be aninterference fit such that the collar is positively located on theintake flange. As such, the outer diameter of the intake flange alongits outer surface may be slightly larger than the internal diameter ofthe collar along its inner surface. The collar may also incorporate arecess along at least a portion of its inner surface. The recess may beconfigured to conform to a lip on the compressor's intake flange or tothe end or another portion of the intake flange. Furthermore, an end ofthe collar opposite from the graduated end may be configured to lieflush with a side surface of the turbocharger's compressor. Thecombination of the snug interference fit, recess, and abuttingarrangement may help the collar stay in place on the flange. A frontportion of the collar, in some cases corresponding to portions of thegraduation, may also drape over the intake flange such that there is asmooth, uninterrupted flow of air from the intake conduit to thecompressor's blades.

The intake conduit may have an internal diameter generally correspondingto the outer diameter of the collar or slightly smaller than the outerdiameter of the collar to form another interference fit. As such, onemay place the intake conduit on the collar (already fitted to the intakeflange) to seal the compressor's intake. Therefore, in some embodiments,the intake conduit may be formed with a relatively constant internaldiameter, from end to end, that supports high air flow. Further, theintake conduit may be shaped and tuned for desired air flowcharacteristic such as increased throttle response and reduced lag inturbocharged applications. Such shaping and tuning may include, but isnot limited to, varying the internal diameter, incorporating chambers,and creating different geometries in the intake conduit to support thedesired air flow characteristics. A clamp or band may be used to tightenthe conduit around the collar. The intake conduit may also incorporateopenings around its diameter, such as slots, that, when tightened aroundthe collar, compress to make a tight seal against the collar. The collarmay also incorporate ribs on its outer surface capable of compressingwhen the intake conduit is fitted thereto, to increase the effectivenessof the seal. Further, the collar may incorporate flanges or vanestherein to direct air flow to the compressor wheel effectively. Saidvanes may be configured in a variety of different fashions and may bestraight or angled depending on application.

The collar may also be formed with a graduated front surface on one endsuch that air flowing from the intake conduit may smoothly transfer fromthe larger diameter of the intake conduit to the smaller diameter of theintake flange. This graduation may take different sizes and shapesdepending on application. Such collars may be formed with differentinternal and external dimensions such that they can be capable ofcoupling different sized intake conduits to different sized intakeflanges and may also be configured to work with naturally aspiratedvehicles by mating to an intake flange of an engine's intake, ratherthan its compressor.

In another embodiment, an air intake system may include an air intakeconduit having a proximal end and a distal end, an air metering devicefitted to the air intake conduit, a collar formed from a rubber-likematerial and having an inner surface for conditioning air flow, and anouter surface having at least a portion thereof configured so that thecollar fits snugly into the air intake conduit. The proximal end of thecollar may include a bead which mates the collar to the proximal end ofthe air intake conduit. A proximal portion of the collar may have agraduated surface for supporting incoming air flow, necking the air downfrom a first diameter intake conduit to a second, smaller diameter foraccurately passing through the air metering device. The graduatedsurface may also have one or more stepped surfaces and one or moreflanges or vanes may be disposed along the graduated surface and/or theinner surface of the collar to direct air flow. The vanes may beconfigured in a variety of different fashions and may be straight orangled depending on application. The collar may be formed from a numberof materials including, but not limited to, polyurethane, silicone, andrubber. Such collars may be formed with different internal and externaldimensions such that they can be capable of coupling to different sizedintake conduits and different sized air metering devices.

The intake conduit may be shaped and tuned for desired air flowcharacteristic such as increased throttle response and reduced lag inturbocharged applications. Such shaping and tuning may include, but isnot limited to, varying the internal diameter, incorporating chambers,and creating different geometries in the intake conduit to support thedesired air flow characteristics.

In application, the collar may be fitted inside the proximal end of anair intake conduit in the intake air stream of an engine. A beadprotruding from the collar may be configured to lie flush with aproximal end of the air intake conduit. This arrangement, in connectionwith a snug interference fit, may help the collar stay in place in theair intake conduit. The collar may also abut an upstream air intakeconduit or other device, such as an air filter. In one example, asilicone coupler is connected to a down stream air intake conduit andcollar on one end, and an upstream air intake conduit on the other.Clamps may be placed at each end of the silicone coupler to seal theintake and securely hold the aforementioned components together. The airintake conduit may be an aftermarket unit that has a larger internaldiameter than an original equipment manufacturer (OEM) part. The largerdiameter of the air intake conduit provides for less restriction to airflow and therefore potentially aids in power production and efficiency.An OEM air metering device, such as a mass air flow sensor, may beremoved from the OEM air intake conduit and inserted into the larger,replacement air intake conduit. The collar necks down the internaldiameter briefly and conditions the air to pass through the air meteringdevice in an accurately measurable manner.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example and not bylimitation in the accompanying figures, in which like referencesindicate similar elements, and in which:

FIG. 1 is an illustration of a perspective view of an embodiment of anintake flow collar 10 in accordance with the teaching of the inventionherein;

FIG. 2 is an illustration of a cross-sectional side view of anembodiment of an intake flow collar 10 in accordance with the teachingof the invention herein;

FIG. 3 is an illustration of a perspective view of an embodiment of anintake flow collar 10 inserted into an air intake conduit 12 inaccordance with the teaching of the invention herein;

FIG. 4 is an illustration of a partial cross-sectional view of anembodiment of an intake flow collar 10 inserted into an air intakeconduit 12 and onto an intake flange 36 of a turbocharger 34 inaccordance with the teaching of the invention herein;

FIG. 5 is an illustration of a perspective view of an embodiment of anintake flow collar 100 in accordance with the teaching of the inventionherein;

FIG. 6 is an illustration of a cross-sectional view of an embodiment ofan air metering reducer collar 640 inserted into an air intake conduit610 in accordance with the teaching of the invention herein;

FIG. 7 is an illustration of a bottom view of an embodiment of an airmetering reducer collar 640 in accordance with the teaching of theinvention herein; and

FIG. 8 is an illustration of a perspective view of an embodiment of anair metering reducer collar 640 in accordance with the teaching of theinvention herein.

Skilled artisans appreciate that elements in the figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the figures maybe exaggerated relative to other elements to help improve theunderstanding of the embodiments of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1 illustrates a perspective view of an embodiment of an air intakeflow device. The flow device may be in the form of a collar and may bemade out a number of materials suitable for use in connection with aninternal combustion engine. In this embodiment, collar 10 is formed frompolyurethane, although in alternative embodiments the collar may be madefrom a number of additional materials such as silicone, rubber, andother materials suitable for a given application. As such, collar 10 isflexible and pliant and has material properties suitable for use inconnection with under-hood heat generated from an internal combustionengine. Moreover, the polyurethane makes installation relatively easy ascollar 10 may be pressed over a turbocharger's intake flange 36 andwithin an air intake conduit 24 (as shown in FIG. 4).

Collar 10 has an inner surface 12, outer surface 14, distal end 16, andproximal end 18. The inner surface 12 has an inner diameter that may beslightly smaller than the outer diameter of an intake flange that it maybe mounted to. In particular, in the case of a turbocharger application,as shown in FIG. 4, the outer diameter of intake flange 36 may beslightly larger than the inner diameter of collar 10. The slightdifference in diameter may provide for a desirable interference fitwhereby the collar 10 may be held tightly about the intake flange 36. Inaddition, collar 10 may be formed with a recess 20 within its interiorsurface 12. Recess 20 may conform to a lip 38 on intake flange 36 andfurther function to hold collar 10 securely on the intake flange.Further, collar may incorporate a collar flange 15. As shown in FIGS.3-4, collar flange 15 may rest flush with a proximal end 28 of an airintake conduit 24 on one side and a turbocharger's 34 compressor housingon the other side. This configuration may further secure therelationship of the intake conduit 24, collar 10, and turbocharger 34from undesirable movement. For different applications, it may bedesirable to form the collar in different forms, such as ellipticalshapes. The elliptical form may be particularly useful in connectionwith coupling the air intake to a throttle body which may also have anelliptical configuration. Furthermore, the collar may be configured foran interference fit, or not, depending on application and may have norecess or more than one recess depending on application and may alsoincorporate a flange, or not, depending on application.

As shown in FIG. 2, collar 10 has a proximal end 18 with a graduatedsurface 52. The graduation, which may take numerous shapes, tends todirect air into the compressor's intake blades. Collar 10 may also beconfigured as shown herein to provide a smooth surface for air to flowfrom the graduation to the interior of intake flange 36. In particular,as shown in FIG. 4, a portion of collar 10, in this case correspondingto the graduated surface, may protrude over the intake flange 36 in thedirection of incoming air. The inner diameter may be similar to, or thesame as, the internal diameter of the intake flange 36. In this manner,the “step” between collar 10 and intake flange 36 may be reduced oreliminated.

Referring to FIGS. 1-2, collar 10 may be formed with one or more ribs 22on its outer surface 14. Ribs 22 may be molded into collar 10 and madefrom the same material. In this embodiment, ribs 22 are configured tocompress when air intake conduit 24 is fitted over collar 10, as shownin FIG. 3. The compression may be accomplished using devices such as anadjustable hose clamp 44 as illustrated in FIG. 4, though alternativemeans of securing are contemplated. In some cases, a clamp may not evenbe necessary depending on the relationship of the components. Thecompression of the ribs 22 helps to complete a seal along the intaketract. Similar to the interference fit arrangement of collar 10 andintake flange 36, air intake conduit 24 may be configured with aslightly smaller internal diameter than the outer diameter of the outersurface of collar 10. Accordingly, a tight seal may be formed whenintake conduit 24 is clamped onto intake flange 36, around collar 10.Several slots 30 may be formed in air intake conduit 24 to help itcompress under pressure. When clamp 44 is tightened, slots 30 maycompress together, effectively shrinking the inner diameter of intakeconduit 24.

FIG. 3 illustrates collar 10 within intake conduit 24. In thisembodiment, intake conduit is formed from cross-linked polyethylene(“XLPE”), although in alternative embodiments, other materialsincluding, but not limited to, aluminum, steel, and other plastics,metals, and composites may be used depending on application. As shown,the internal diameter of intake conduit is relatively constant fromdistal end 26 to proximal end 28. Dimensions of intake conduit 24 may bevaried according to application. As set forth above, several slots 30may be formed in air intake conduit 24 to help it compress underpressure such as when used in connection with a clamp 44 as shown inFIG. 4. Other well-known variations may be used to enable intake conduit24 to compress according to application.

FIG. 4 illustrates collar 10 in connection with intake conduit 24 andturbocharger 34 as such devices may be coupled together. As shown,intake conduit 24 may be coupled to turbocharger 34 with only one clamp44, rather than two clamps that may be used in connection with aconventional coupling. As such, there are fewer parts to assemble,tighten, and potentially come loose. In application, air will travelfrom an air filter, through intake conduit 24, through the graduatedportion 52 of collar 10 into the turbocharger's 34 compressor intakeflange 36, and thereafter be compressed by the turbocharger.

In the embodiment shown in FIGS. 1-4, the collar has an outer diameterof approximately 3.875 inches and an inner diameter of approximately2.875 inches. Along inner surface 12, recess 20 has a diameter ofapproximately 3 inches and is approximately 0.25 inches wide and 0.125inches deep. As set forth above, collar 10 has a proximal end 18 with agraduated surface 52 configured to direct air to the turbocharger. Thegraduation is approximately 0.625 inches wide, the graduation startingwith a diameter of approximately 3.75 inches and tapering down toapproximately 2.875 inches to correspond to the internal diameter ofintake flange 36.

FIG. 5 illustrates an alternative collar 100 which may be formed withone or more vanes 170 for directing airflow into the intake. Similar tocollar 10, collar 100 may have an inner surface 120, outer surface 140,distal end 160, and proximal end 180. The inner surface 120 may have aninner diameter that may be slightly smaller than the outer diameter ofan intake flange that it may be mounted to. In addition, collar 100 maybe formed with a recess 200 within its interior surface 120. Fordifferent applications, it may be desirable to form the collar indifferent forms, such as elliptical shapes. Collar 100 may have aproximal end 180 with a graduated surface 520 and may be formed with oneor more ribs 220 on its outer surface 140.

It has been noticed that air being drawn in large volumes into distalside 26 (FIG. 3) exhibits a tendency to reduce the flow rate of airpassing by a typical air flow meter (mass air flow sensor, MAS). As isdepicted in FIG. 6, this occurs because the wider diameter of theaforementioned conduits 610 causes air to move at a slower rate (despitebeing a greater air volume) than expected by a stock MAS 630, causingthe MAS 630 to react as if the vehicle was moving more slowly andrequiring less power. In some other cases, the air flowing through theMAS may become unpredictable and thus difficult to accurately measure.This performance sapping phenomenon is contrary to the actual increasedair flow in the conduit, thereby causing a conundrum with using largerconduits to supply greater air flow and to increase power supplied bythe engine. In response, mass air sensor reducer collar (MASRC) 640, canbe inserted into the intake airflow conduit system just upstream of theMAS 630. MASRC 640 can be configured with a wider entrance throatopening 650 (4.5 inches) than an exit throat opening 660 (3.2 inches),causing an increase in velocity of air past MAS 630 (flow: left toright), and thereby velocity-compensating for the otherwise increased,but slower, flow of intake air. Seven vanes 620 can be space generallyequidistantly around the inner circumference of MASRC 640. Althoughstraight vane geometry is shown, vanes also may be slightly curved, asis shown with vane 170 in FIG. 5. Of course, other numbers, geometries,depths, widths, and placement of vanes can be used. Vanes 620 also tendto be slightly wider and deeper at entrance throat opening 650 than atexit throat opening 660. The increased velocity of air is properlysensed by MAS 630 allowing for a corresponding signal to be sent to anengine's electronic control unit (ECU), to adjust the parameters of theengine. For example, the ECU may increase fuel in response to thegreater air flow.

FIG. 7 depicts a bottom view of MASRC 640 with the section illustratingMASRC 640 in FIG. 6 being depicted through the A-A′ section of FIG. 7.In FIG. 7, MASRC 640 has five ribbed braces 610 positioned around itscircumference. Each ribbed brace is configured to produce a snug fit andseal in the conduit in which it is inserted and contacted. The minorportion of vanes 620 can be seen in exit throat 660. As is seen in FIG.7, exit throat 660 tends to be configured with a narrower diameter thanthe entrance throat around which can be seen entrance seal bead 635.

FIG. 8 illustrates a perspective view of MASRC 640, taken from thecollar bottom. MASRC 640 can include body 605, braces 610 with ribs(generally at 615) and entrance seal bead 635. Vanes 620 can beinterposed in inner throat wall 645 and a flare 665 may extend fromentrance throat opening 650 to throat inflection region 655. The throatcontinues from inflection region 655 to exit throat opening 660. Body605, braces 610 and ribs 615 can be made of a resilient, elastomericrubber-like material to facilitate manufacturing and installation.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any element(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature or element of any or all the claims. As used herein, the terms“comprises,” “comprising,” or any other variation thereof, are intendedto cover a non-exclusive inclusion, such that a process, method,article, or apparatus that comprises a list of elements does not includeonly those elements but may include other elements not expressly listedor inherent to such process, method, article, or apparatus. The terms“a” or “an”, as used herein, are defined as one, or more than one. Theterm “plurality”, as used herein, is defined as two, or more than two.The term “another”, as used herein, is defined as at least a second ormore. The terms “including” and/or “having”, as used herein, are definedas “comprising” (i.e., open language). The term “attached”, as usedherein, is defined as connected, although not necessarily directly.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the description herein of specificembodiments is not intended to limit the invention to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the invention, as defined by the appended claims.

1. An air intake system comprising: an air intake conduit having aproximal end and a distal end; an air metering device fitted to the airintake conduit, the air metering device configured to measure acharacteristic of incoming air flow; a collar having an inner surface,one or more vanes disposed along the inner surface of the collar, anouter surface, at least a portion of the outer surface configured sothat the collar fits snugly into a proximal portion of the air intakeconduit, a proximal end having a bead, the bead mating the collar to theproximal end of the air intake conduit, a proximal portion of the collarhaving a graduated surface for supporting incoming air flow, and adistal end; wherein the collar is configured to direct air flowdownstream, and to the air metering device.
 2. The air intake system ofclaim 1, wherein the collar further comprises one or more compressibleribs formed on its outer surface.
 3. The air intake system of claim 1,wherein the air metering device comprises a mass air flow sensor.
 4. Theair intake system of claim 1, wherein the proximal end of the air intakeconduit is coupled to an air filtering device.
 5. The air intake systemof claim 1, wherein the graduated surface of the collar has one or morestepped surfaces.
 6. The air intake system of claim 1, wherein thecollar is comprised of a material selected from the group consisting ofpolyurethane, silicone, and rubber.
 7. The air intake system of claim 1,wherein the diameter of the inner surface of the collar tapers from theproximal end to the distal end.
 8. The air intake system of claim 1,wherein a portion of the graduated surface of the collar has an internaldiameter substantially equivalent to an inner diameter of an upstreamconduit.
 9. The air intake system of claim 1, wherein the collar bead isfit between the proximal end of the air intake conduit and a distal endof an upstream conduit.
 10. The air intake system of claim 1, whereinthe collar mating surface is fit between the proximal end of the airintake conduit and a distal end of an upstream conduit.
 11. The airintake system of claim 1, wherein the collar is generally ellipticallyshaped.
 12. An air intake collar comprising: a malleable collar havingan inner surface with a diameter tapering from a proximal end to adistal end of the collar, one or more vanes disposed along the innersurface of the collar, an outer surface configured with ribs so as toconformingly fit within an air intake conduit, the proximal end of thecollar having a mating surface configured to abut a proximal end of theair intake conduit, a proximal portion of the collar having a graduatedsurface for supporting incoming air flow, wherein the collar isconfigured to direct air flow downstream, and to a vehicle's airmetering device.
 13. The air intake collar of claim 12, wherein thegraduated surface of the collar has one or more stepped surfaces. 14.The air intake collar of claim 12, wherein the collar is comprised of amaterial selected from the group consisting of polyurethane, silicone,and rubber.
 15. The air intake collar of claim 12, wherein a portion ofthe graduated proximal surface of the collar has an internal diametersubstantially equivalent to an inner diameter of an upstream conduit.16. The air intake system of claim 12, wherein the collar mating surfaceis fit between the proximal end of the air intake conduit and a distalend of an upstream conduit.
 17. The air intake system of claim 12,wherein the ribs are configured to compress upon insertion into an airintake conduit.
 18. The air intake system of claim 12, wherein thecollar is generally elliptically shaped.
 19. An air intake flow devicecomprising: a collar having an inner surface, an outer surfaceconfigured to conformingly fit within an air intake conduit, a proximalend having a mating surface configured to abut a proximal end of an airintake conduit, and means for conditioning air flow to a vehicle's airmetering device such that the air flow is accurately reported to anelectronic control unit by the air metering device.
 20. The air intakesystem of claim 19, wherein the air intake flow device is comprised of amaterial selected from the group consisting of polyurethane, silicone,and rubber.